Method of making cables



Jan. Z6, 1943 L. S. BURGETT METHOD OF MAKING CABLES 5 sheets-sheet' 1 Filed Sept. 30, 1940 in y BY www W/ Jan. 26,' 1943 L 5' BURGETT METHOD OF MAKING CABLES -Filed Sept. 30. 1940 BY /fMQ/M Jan. 26, 1943 L, s. BURGETT. 2,309,439

METHOD OF MAKING CABLES Filed Sept. 50, 1940 5 Sheets-Sheet 3 low l INVENTOR. gn/7 5l/rye# my ff Jan 25, 1943 L. s. BURGETT 2,309,439

METHOD OF MAKING CABLES Filed Sept. 30, 1940 K 5 Sheets-Sheet 4 Jan. 26, 1943 1 n. s. BURGETT 2,309,439

METHOD OF MAKING CABLES Filed Sept.' 3Q,..- 1940 5 Sheets-Sheetv 5 I 1ML WyZ @wma/13 Patented Jan. 26, 1943 UNITED METHOD OF MAKING CABLES Lynn S. Burgett, Euclid, Ohio, assignor to The Clark Controller Company, Cleveland, Ohio, a

corporation of Ohio Application September 30, 1940, Serial No. 359,107

3 Claims.

This invention relates to methods for making electric cables, particularly cables for carrying currents oi great amperage, and constructed to be iiexible.

Cables of the class referred to are used for various purposes wherein the lcurrent to be conducted by the cable is of great amperage and wherein the cable must bend in use, one illustrative use being to conduct welding current to a moving welding gun or machine, in which case any lack of exibility in the cable would interfere with the free movement of the gun by the operator thereof.

The invention comprises various improvements over prior cables of this class and the methods for making them which appear in the following objects of the invention.

It is among the objects of the invention:

To provide generally a method for making an electric cable of relatively great amperage capacity having an improved quality of exibility;

To provide an improved method for making connections between the conductors of a multiconductor cable and end terminals for the conductors;

To provide an improved method for connecting the conductors of a multi-conductor Cable in groups to corresponding end terminals and completeiy enclosing the conductors in the cable;

To provide, for cables of the multi-conductor class, improved means and method for insulating the conductors from each other.

To provide an improved method for electrically and mechanically connecting the terminal ends of the conductors of a multi-conductor cable in two groups to a pair of terminal heads respectively, with the terminal ends of both groups completely enclosed and covered by the terminal heads.

Other objects will be apparent to those skilled in the art to which my invention appertains.

My invention is fully disclosed in the following description taken in connection with the accompanying drawings, in which;

Fig. 1 is a side elevational view of an electric cable embodying my invention, and illustrating one construction of terminal at the ends thereof;

Fig. 2 is a longitudinal sectional view of the right hand end of the cable of Fig. 1 and drawn to enlarged scale;

Fig. 3 is a sectional view taken from the plane 3-3 of Fig. 2 and with some of the parts thereof omitted for simplicity;

Fig, 4 is a View taken in the direction 0f the arrow 4 of Fig. 2;

Fig. 5 is a cross-sectional view taken from the plane 5 5 of Fig. 2;

Figs. 6 and 7 are respectively plan and crosssectional views of an insulator which I may employ in the cable of Fig. 2, Fig. '7 being taken from the plane l--l of Fig. 6, and these views illustrating the sheet form in which the insulator is rst made, the aforesaid Fig. 5 illustrating the insulator in its assembled condition in the cable;

Fig. 8 is a view in some respects diagrammatic for clearness, illustrating the overlapping of opposite edges of the insulator of Fig. 7 when it is assembled in the cable as in Fig, 5;

Fig. 9 is a view, a part of which is in elevation, a part of which is in longitudinal section, and a part of which' has an outer portion broken away, illustrating the construction of an outer casing or hose of the cable of Fig. 2;

Fig. 10 is a view similar to a part of Fig. 9 illustrating a modiiication;

Fig. 11 is a cross-sectional view taken from the plane II-ll of Fig. 9;

Fig. 12 is a view similar to a part of Fig. 2 and illustrating certain steps of method which I may employ in securing conductors of the cable to a terminal thereof, the view being taken approximately on the plane |2-I2 of Fig. 4;

Fig, 13 is a view in elevation illustrating a modified form of a terminal connector;

Fig. 14 is a view illustrating in longitudinal section another modication of one of the terminals of Fig. 2 or of Fig. 13;

Figs. 15 to 2O are, collectively, views illustrating a method for assembling a terminal connector and conductors of a cable embodying my invention in one form and which may be employed with the form of Figs. 1 to 12;

Fig. 15 is a view showing a cable similar to that of Fig. 2 but showing modications; and showing some of the steps of the method;

Fig. 16 is a fragmentary View taken from the plane 12 of Fig. 15;

Fig. 17 is a View similar to Fig. 15 showing other steps of the method;

Fig. 18 is a view taken from the plane i8 of Fig. 15 showing another step of the method and with' some of the parts of Fig. 15 omitted for simplification;

Fig. 19 is a View of the cable of Fig. 15 showing other steps of the method;

Fig. 20 is a view taken from the plane 2li of Fig. 19 showing another step of the process- Referring to Fig. 1 oi the drawings I have shown at l the cable proper, and at 2-2 end connectors therefor. The connectors 2 2 may be alike or different, as will appear hereinafter, but as shown in Fig. l, the connectors are alike and each comprises terminals 3 and 4 insulated from each other by an insulator 33; and threaded openings IBG-IGS are provided in the opposite connectors 2 whereby cooling fluid may be conducted into the cable at one end and out at the other. The terminals 3 are connected to one set of conductors in the cable, and the terminals l connected to another set of conductors, and as will be explained hereinafter, the terminals 3 and 4 may be constructed in various types to adapt them to be connected to various types of apparatus, such for example as a transformer at one end of the cable and a welding gun at the other end, when the cable is to be used to carry welding current.

The right hand connector 2 and the corresponding end of the cable are shown in longitudinal section in Fig. 2, and coordinate therewith, the terminals 3 and 4 are shown in Figs. 3 and 4 in elevation.

The main body of the cable as shown in Figs. 2 and 5, comprises a plurality of conductors in groups alternately arranged, as for example at 5 5-5 and 6 5-5 in Fig. 5; and disposed around a longitudinal core of rubber or the like 'I and insulated from each other by a convoluted insulator 8 of rubber or like flexible insulating material, and surrounded by a tubular casing or hose 9.

rlhe conductors 5 and 6 are preferably made up in a well known manner, of thread wires and strands woven or twisted into rope form to render them flexible.

To simplify the drawings, particularly Fig. 2 the conductors 5 and 6 are illustrated as lying parallel to the axis of the cable, and in fact, may be disposed in this relationship, but I prefer t dispose the conductors in helical arrangement around the axis, for example as illustrated and described in the pending patent application of Mackworth G. Rees, Serial Number 201,360, led April 1l, 1938, for Current delivering and conducting means.

In assembling the conductors and 6, and the insulator 8, the conductors 6 5 may rst be laid around the core l, and the insulator 8 laid thereon; and the conductors 5 5 then laid in convolutions in the insulator, to be presently described, and then the casing or hose 9 is telescoped longitudinally over the insulator and conductors, the hose or casing being shorter than the insulator and conductors, so that the latter project out of the opposite ends thereof.

The insulator 8 is shown in Figs. 5 and 7 in the form in which it is first made. Preferably it is made from rubber by an extrusion or other process into generally planar or sheet form, comprising flat or planar portions I8 II), and spaced loop portions or convolutions II II between the planar portions, and in the present illustrative instance, where there are to be three conductors 5 5 5, there will be three such convolutions. The outermost planar portion Il) at each side of the insulator, terminates in bent thinned edges I2 and I3. The sheet 8 may be made of considerable length, and at the time of making a cable of any chosen length, a piece from such long strip is cut oif to approximately the necessary length, to be referred to, and is then folded around the core 'I to cause it to take up the cross-sectional shape shown in Fig. 5, wherein the loop portions I I are disposed so that the conductors 5 5 may be laid therein and wherein the planar portions Ill-I0 bend so that they define a longitudinal cylinder firmly or tightly engaged with the inner wall of the hose 9 when telescoped thereover, as plainly shown in Fig. 5. The edges I2 and I3 of the strip, when bent into the form of Fig. 5 are disposed approximately as shown in Fig. 8.

Bending the sheet insulator from the form of Fig. 7 to the condition in Fig. 5, causes the convolutions I I, as shown for one of them in Fig. 5, to become divergent, and causes the side walls I4, Figs. 5 and 7, of each convolution to be disposed generally radially, as shown in Fig. 5.

It follows that when the core 'I, insulator 8, conductors 5 5 and 6 6 and the outer sleeve or cover 9 are assembled as shown in Fig. 5, or Fig. 2, there are longitudinal passageways I5-I5 along the sides of the conductors 5 5, and longitudinal passageways IB-IS along the sides of the conductors 6 5, the passageways I5 I5 being separated by the insulator 8 from the passageways I6 I6, and the conductors 5 being insulated from the conductors 6.

If the conductors 5 5 and 6 5 are to be disposed in helical arrangement around the core, the sheet 8 is wrapped around the core 'I so that its edge portions overlap on a helical zone thereby disposing the convolutions II in helical arrangement.

The assembled cable proper, made as above described, is now joined to the connectors 2 2 as followsy and as shown for one of them in Fig. 2.

The terminal 3 is joined to a head Il, preferably by being made integral therewith as a casting of copper' or other highly electrically conducting material, and a material to which solder or other fusible metal will adhere, for a purpose to be described. The head II comprises a central cylindrical opening I8, the periphery of which is outwardly radially recessed by a plurality, such as three, circular recesses I9 I9, and inwardly toward the cable proper and beyond the recesses, the head I'I has an annular shoulder 20, into which is fitted and secured, for example by soldering, a short tubular sleeve 2|, slightly larger in outside diameter than the inside diameter of the outer hose or casing, and larger on its inside diameter than the diameter cf the assembled conductors and insulator. The head I'I is also provided with a plurality of threaded holes 22,

For the next step of the assembling operation, the conductors 5 and 6 and the insulator 8 are telescoped or projected through the sleeve 2| and opening I8 of the head I1, and thc hose 9 is concurrently telescoped over the sleeve 2 I, which stretches it tight thereon, to seal it liquid tight therewith, and it is further sealed and secured thereon against displacement by a wrapping of wire shown at 23, Figs. l and 2. The outer conductors 5 5 are now bent outwardly radially, as shown at 24, Fig. 2, and laid in the recesses I9, and an assembling sleeve 25 is telescoped into the opening I8 substantially fitting the same and forcing the ends of the conductors into the recesses I9, the wall of the recesses and adjacent parts of the sleeve 25 constituting pockets into which the ends of the conductors are firmly lodged. The three conductors 5 are disposed in this manner and their end portions which extend beyond the head Il are then cut oif as at 25 preferably flush with a transverse plane 21 on the head I'I. Solder or other fusible metal is then applied by well known heating means to the ends of the conductors 5, at 26 in the recesses I9,

to securely join the Wires thereof together, and to integrally unite them with the head Il at the walls of the recesses I9.

The other terminal 4 comprises a head 28, Figs. 2 and 4, having a transverse planar face 29, and an interior recess 3d, and an inwardly open pocket 3l. The ends of the conductors 6 are now cut off as at 32, Fig, 2, to a measured length beyond the plane 2'! referred to, and the face 29 of the head 23 is placed upon the face 2"! of the head Il with an insulating washer 33 therebetween, and bolts 34--34 are projected through insulating sleeves 35 in the head 28 and through perforations in the insulator 33 and threaded into the threaded holes 22 to rigidly seal and clamp the head 28 upon the head I'l with the ends of the conductors in the pocket Si.

The head 28 has a plurality, such as two, pipe threaded openings It and IMA, extending therethrough and communicating with the chamber 3U.

The threaded openings llli and IBSA may be variously disposed. As shown in Fig. 4r, in the form illustrated, they are disposed at an angle of approximately l2() degrees with each other but may, as will be understood, be disposed diametrically opposite, or otherwise.

Before the head 28 is bolted on, as described, the insulator 8 is cut off at a point within the chamber 33, for example, as shown at 36, short of the pocketl.

For the next step of the assembling operation, the cable, illustrated thus far in horizontal position, is supported vertically, as indicated in Fig. l2, which disposes the pocket 3l at the lowermost point of the head 28. By means of a blow torch or other heat supplying means 3l, the head 28, and particularly the pocket 3| thereof, are heated, thus heating the end portions of the conductors -t and a wire or stick 38 of solder or other fusible metal is projected through one of the said pipe threaded openings, for example the opening |95, and into engagement with the hot head 23 and conductors and the solder melts and flows around the conductors filling the pocket 3l therearound and up to a level such as that shown at 33 joining the conductors to each other and to the wall of the pocket. This operation may be viewed through the other opening IDEA, and the filling with solder may therefore be stopped at a suitable observed level 39.

Upon removing the source of heat, and the soldering stick 33, the solder sets and integrally joins the conductors 6 to the head 28.

The opposite end of the cable is assembled in the same way as that just described. The electric circuit through the cable will be seen to be from one of the terminals, say the terminal 4 from a current source, through the inner conductors l, out at the other terminal 4, to apparatus to be energized and back therefrom through the terminal 3, and through the outer conductors E, to the other terminal 3, and to the source, as an illustrative use.

Cooling liquid may be circulated through the cable. By one method, one of the openings, sav MGA, is closed by a plug 40, Fig. 4, and a coolingliquid conduit has a threaded terminal thereof threaded into the other opening 1&6. Cooling liquid therefore will enter the chamber 3! and there divide, part owing around the conductors (iand longitudinally through the passages lil-Iii and out through a corresponding charnber and conduit at the other end of the cable: and part flowing from the chamber 30 through the opening I8, and longitudinally through the passageways l5-l5 and out at the other end of the cable; thus iowing in two streams, each stream in direct Contact with the metal of the conductors of one of the groups of conductors, and each stream insulated from the other by the insulator 8 through the major part of the cable.

The assembling sleeve 25 may be left in the position of use, and as illustrated in 2, or after the conductors` 5 have been soldered into the recesses I9, it may be removed. In either case it may if desired be made of metal.

The terminals 3 and 4 are in the form of lugs with open ended slots to receive bolts ior clampthem on to an apparatus part.

In Fig. 13 is illustrated a modication, in which the heads l'lA and 28A and the insulating washer 33 and bolts 34 and sleeve 2l are similar to those in the form of Fig. 2, but the terminals thereof are different. The terminal connected to the head 28A is in the form of a longitudinally extending tongue fil; having a perforation l2 therein by which it .may be bolted to a point of use, The terminal d3 connected to the head llA is provided With faces 44, 45, 4E and bolt holes ll and 48 and a threaded bolt hole 53; laminated flexible conductors may therefore be bolted to this terminal by bolts projecting through the bolt hole i8 or into the threaded bolt hole 53 and the laminated conductors lying against one of the faces 4t to 45 in a well known manner, or the terminal 43 may be bolted to a point of use by a bolt through the hole Gl.

In Fig. 14, is illustrated a modiiication of the outer head 28B corresponding to the head 28. This head has the chamber 3D and pocket 3i and holes 43 for the bolts, as in the form of 2. The electrical terminal 50 projects axially from the head and has threads 5l on the end thereof by which it may be screwed into an apparatus part, such as a welding gun, at the peint of use, and has a cooling iiuid duct 32 opening outwardly and therefore communicating with a corresponding duct ,in the part or gun to which the terminal is threadedly joined, and the duct 52 communicates with the chamber 3d. With this form, as will be apparent, the cooling liquid which flows through the cable, may also flow through the part or gun to which the terminal lill is connected.

Referring now to Figs. 9, 1G and il, which illustrate more particularly the construction of the outer hose or casing shown at S, in Figs. 2 and 5. the hose is seen to comprise an outer layer or tube 53, and an inner tube of rubber 54, with a layer of cord 55 therebetween. In prior hoses, threads or small. cords of woven arrangement have been disposed between inner and outer layers of rubber. In some cases, because of the woven character of the threads, the threads extend longitudinally of the hose or in helical direction therethrough, some following a right hand helix and others a left hand helix. In some cases, because of the woven character of the threads, seme of them extend substantially parallel to the axis and others helically around the hose, In either case, and in all prior hoses of which I have knowledge, when the hose bends, at least some of the cords or threads of the fabric are put under tension, which resists the bending of the hose and renders it stiff and of little flexibility, and causes the bent hose to buckle and assume an elliptical crosssectional form.

In the hose of the present invention, the thread or cord 55 is solely helical, havinCY no parts that are put under tension When the hose bends, and .ie hose therefore has substantially the same flexibility as if it were made wholly of rubber and without the reinforcing thread or cord, and may be bent upon a relatively short radius without deforming its circular cross section and when used as the covering hos-e or casing of a cable such as that described above, increases enormously the flexibility of the cable, over prior cables. For example, as an experiment I have found that a six-conductor cable, constructed and assembled complete as described hereinbefore and as illustrated and of such a size that the outside diameter of the assembled hose is 1% inches, can be wrapped freely spirally around a 6 inch diameter pipe without materially distorting the cross-sectional circular form. The helical cord 55 at the same time prevents distortion of the casing by cooling fluid under pressure. Furthermore, the cable is rendered flexible in the torsional direction by the hose of this construction. A cable such as that illustrated and of 1% inches outside diameter and say 8 feet long can be twisted merely by the force of the human hands to approximately 450 degrees from normal in the direction that winds up the helix of the conductors from the usual helical angle thereof and '120 degrees from normal in the other direction.

In Fig. 9, I have illustrated the cord 55 as being a single cord, such as a cord of cotton, but it will be understood that the cord may be made of multiple parallel strands, or threads.

In making the hose of Fig. 9, a suitable process is to extrude the inner tube 54 and mount it on a mandril and then wind the cord helically thereon, at such a pitch that there is a space 53 between adjacent convolutions. The space may be commensurable with the diameter of the cord. Then an extruded outer tube 53 is telescoped over the cords. Then the two tubes are vulcanized together, being thereby integrally united through the cord convolutions and on the portions 56 between adjacent convolutions.

In the modification of Fig. 10, the cord 55A is wound at such a pitch that adjacent convolutions of the cord touch or substantially touch each other and the outer and inner tubes 50 and 54 are vulcanized together primarily through the fibers of the cord.

In Figs. to 2i) is illustrated another method for assembling and making the cable in connection with certain modifications of details thereof.

Referring to Fig. 15 and Fig. 18, the walls of the recesses I 9 in the head I1, before assembling with the sleeve 9 and the conductors, are tinned preferably in an electric furnace whereby intimate integral union between a heavy coat of tinning metal and the metal of the head may be insured. The conductors 5, `before cutting them off flush with the face 21 as described above, have tubular` bands or collars 51 tightly clamped there around. These bands, which are preferably made from sheet metal and which in some cases it may be desirable to coat inside and out with a plating or coating of tin or the like, are then forced into the recesses I9 by any suitable tool, for example a pair of pliers, forcing the bands into intimate engagement with the tinned walls of the recesses IS, and this may give a relatively flat form to the inner portion of the ring and conductor there within, as plainly shown in Fig. 1S.

A tube of metal such as steel 59 is then telescoped within the bands 51 to hold them in the recesses while the projecting outer ends of the conductors 5 5 are being cut off along the face 21, and this latter operation may be performed by a sharp-edged tool such as a chisel 60, Figs. 15 and 18, the face of which is laid co-planar with the head face 21 and driven through the conductor with a hammer, the tube 59 taking up the force of the blows and preventing the bands 51 from being dislodged. The tube 59 may then be removed. During these operations, the head I1 may be held in a suitable vise.

The next step is to solder or otherwise fusingly join the bands 51 to the walls of the recesses I9. During this step of the process the abovementioned face 21 is maintained in the horizontal position illustrated. Heat shields 6I are temporarily inserted between each of the bands 51 and the rubber insulator 8 to protect the latter from heat, and an electric heater is applied comprising massive blocks 52 and 63 positioned to embrace the head I1 therebetween with suitable clamping pressure. Electric current is then passed from one block, through the head I1 to the other block, for example by connecting the blocks as shown in Fig. 17 to the secondary 64 of a transformer, the primary of which may be energized by a switch E5. The electric current heats the head I1 and the tinned walls of the recesses I9, and the bands 51 and the conductors 5 and when sufficiently heated, solder or other fusible metal in the form of a stick G4 is fed into the recesses of the conductors and the thin recesses at the inner latter parts of the bands and between the bands and the recess walls effecting an integral juncture between the conductors and the head, the heat being insulated from the insulator 8 by the shields 6I. The shields may then be removed or may be removed when the fusible metal has firmly set.

If desired, the tube 59 may be retained in its aforesaid position during this operation and until the fusible metal has set, to concurrently hold the bands in the recesses with pressure, and if the inner end of the tube 59 be slightly conical as shown at 55, the tube may in fact function as a wedge to force the bands into the recesses and hold them there until soldered in place.

While the conductor blocks 62 and 63 may be clamped upon the head I1 in any well-known manner, I prefer to have them mounted upon the jaws of tongs and held toward each other by a spring not shown in which case the electric current is conducted through the jaws of the tongs. Such tongs are well-known.

After the heating current has been interrupted and the blocks 62-63 removed, and the fusible metal has been allowed to set, the three conductors 6--6 are drawn together into a close Group and a circular band 66 is constrictingly clamped therearound. This clamping and bending operation of the band 66 is preferably performed by a tool which maintains the band in circular crosssectional configuration as shown in Fig. 16. The axial position of the band is determined by measuring to it from the face 21 of the head I1 for a purpose which will become apparent, and the outer ends of the conductors B are then cut off along' the outer end 61 of the band 66, suitable known tool means being provided to hold the band 66 rigidly while this step of the process is being performed by a tool for example a chisel such as that referred to above and shown at 50.

While as stated the tool for this purpose may be any well-known tool, in some cases I prefer to employ a tool such as indicated in broken line in Fig. and comprising a block 68 temporarily secured to the head Il by screws 69 threaded into the threaded openings 22 of the head to mount it thereon, and having jaws, for example three in number, '10, arranged to be forcibly moved radially inwardly by screws ll, three of such jaws and screws being provided; and the upper face 12 of the block 68 providing a surface flush with which the outer end of the :band 66 may be located and along which the conductors 6-6 may be `cut off. rIhe block 72 may then be removed. It Will be understood of course that the tube 59 has already been removed before this step of the process is performed.

Referring now to Figs. 19 and 20, the cable as assembled thus far is supported above so that the horizontal face 21 faces downwardly. The other head 28 is now bolted on to the head Il as described hereinbefore by bolts 34 and at the time of putting it in position to be bolted on, the conductors 6 6 with the band 66 therearound is introduced into the pocket Si in the head 28. The pocket 3l is preferably cylindrical in for-m and` of a diameter slightly larger than the outer diameter of the band 66 as plainly shown in Fig. 19 leaving a small space 13.

The head 23 and the walls or" the pocket 3l, the ring ES and the ends of the conductors 6 are now heated by electric current by means or" the aforesaid or similar blocks 63 clamped upon the head 28, see Fig. 20, and electric current passed therethrough. The conductors and the band receive heat from the head where they contact with the inner Wall of the pocket 3|. This pocket was previously tinned in a manner the same as or simliar to that described for the recess walls I9. When the conductors, the band and the pocket walls have attained a suitable temperature, fusible metal is fed into the same by a rod 3S or the like projected through the opening H15 as described for the iirst form iilling all of the interstices around and Within the conductors .up to a level as viewed through the other opening IA, providing, when the heating has been discontinued and the metal has set, an integral bond between the conductors and the head.

My invention is not limited to the exact details of construction illustrated and described. Changes and modifications may be made within the spirit of my invention without sacricing its advantages, and within the scope of the appended claims.

This application is in part divisional from and in part a continuation of the subject matter of my pending application Serial Number 323,971, led March 14, 1940, for improvements in Electric cables. Subject matter illustrated and described herein but not claimed is being claimed in my co-pending applications, Serial No. 356,462, led September 12, 1940, and Serial No. 356,463, led September l2, 1940.

I claim:

1. The method of assembling parts of a cable of the type comprising a plurality of conductors and a head having an opening therethrough and recesses in the wall of the opening and a head yhaving a central pocket therein which includes: tinning the walls of the recesses; projecting all of the conductors through the opening; arranging some of the conductor end portions in an outer group radially outwardly from the cable axis; forming metal bands and clamping them on the end portions of the group at points inwardly of their ends; disposing the end Iportions and bands in the receses; cutting oir the outer ends of the conductors beyond the bands; heating the conductor end portions and walls of the recesses; soldering the conductor end portions and bands to the walls of the recesses; tinning the wall of the pocket; arranging the other conductor end portions in a group radially inwardly of the rst group; forming a metal band and clamping it around the inner group; cutting oi the conductor end portions of the inner group at the band; securing the two heads together with the inner group and their band disposed in the pocket; heating the wall of the pocket; applying solder in the pocket to join the disposed band and conductors to the wall of the pocket.

2. The method oi assembling parts of a cable of the type comprising a plurality of conductors and a head having an opening therethrough substantially co-axial with the cable and a head having a pocket therein aligned with the opening which includes: projecting all of the conductors through the opening; arranging some of the conductor end portions in an outer group radially outwardly from the cable axis; disposing the end portions along the wall of the opening with their outer ends axially beyond the opening; cutting off the outer ends of the conductors at the opening; heating the conductor end portions and the wall of the opening and soldering the conductor end portions to the wall of the opening; arranging the other conductor end portions in a group radially inwardly of the first group and aligned with the opening; causing the conductor end portions of the inner group to extend to a measured length beyond said opening; securing the two heads together with the inner group end portions disposed in the pocket; heating the inner group end portions and the wall of `the pocket; applying solder in the pocket to join the inner group end portions to each other and to the wall of the pocket.

3. The method of assembling the conductors and terminals of a cable of the type comprising two groups of insulated conductors and two terminal heads one of which is provided with an opening therethrough having longitudinal recesses in the wall of the opening, and the other of which is of cup form and provided with a pocket aligned with the opening, and provided with an aperture through its cup wall which includes: projecting all of the conductors through the opening and disposing the end portions of the conductors of one group in the recesses and soldering them to the Walls of the recesses and cutting them oit beyond the recesses; causing the other group of conductors to extend beyond said opening and cutting them oi to a measured length beyond the recesses, disposing the end portions of the other group of conductors within the pocket of the cup form head; securing the cup form head to the said one head in insulated relation thereto by axially directed securing force; disposing the cup form head in upwardly open position; introducing fusible metal through the said aperture and securing the end portions of the conductors of said other group to each other and to the pocket wall by fusing the fusible metal by applying external heat to the cup wall.

LYNN S. BURGETI'. 

